Method of alloying ferrous material with magnesium injection agent

ABSTRACT

A treatment agent and method to introduce magnesium into ferrous material. The treatment agent includes a mixture of high melting temperature particles and magnesium particles. The content of high melting temperature particles in the particle mixture is present in an effective amount to inhibit the complete conversion of the magnesium particles into molten magnesium prior to the magnesium particles entering the ferrous material. The method describes the efficient treatment of molten ferrous material with these particles.

This patent application is a divisional patent application of co-pendingU.S. patent application Ser. No. 09/546,017 filed Apr. 10, 2000, andincorporated herein by reference.

The present invention relates to a composition of an agent and a methodfor the treatment of molten ferrous metal, and more particularly to amagnesium-containing agent and method for the treatment of moltenferrous metal.

BACKGROUND OF THE INVENTION

Cast iron is primarily an iron alloy that contains carbon and silicon.Wide variations of the properties of cast iron material can be achievedby varying the amount of carbon and silicon, and by adding variousmetallic alloys to the cast iron. Commercial cast irons include gray,ductile, malleable, compacted graphite and white cast iron, amongothers. With the exception of white cast iron, the cast iron steels havea common micro-structure that consists of a graphite phase and a matrixthat may be ferritic, pearlitic, bainitic, tempered martensitic, orcombinations thereof. Gray iron has flake shaped graphite, ductile ironhas nodular or spherically shaped graphite, compacted graphite iron(also called vermicular graphite iron) is intermediate between thesetwo, and malleable iron has irregularly shaped globular graphite that isformed during tempering of white cast iron. White cast irons do not haveany graphite in the microstructures, but instead the carbon is presentin the form of cementite (iron carbide). Cast irons are also classifiedas either unalloyed cast irons or alloyed cast irons. Unalloyed castirons are essentially iron-carbon-silicon alloys with only trace amountsof other elements. Alloyed cast irons are considered to be those castingalloys based upon iron-carbon-silicon systems that contain one or morealloying elements that are intentionally added to enhance one or moreuseful properties of the cast iron.

In the production of ductile and compacted graphite cast iron, puremagnesium or alloys having varying amounts of magnesium are added tomolten cast iron. The addition of the magnesium to the cast ironimproves the strength properties of the cast iron by modifying thegraphite matrix in the cast iron. Various techniques can be used tointroduce the magnesium into the cast iron. Small particles of puremagnesium can be directly added to the molten cast iron. The magnesiumparticles can be plunged into a ladle of the molten cast iron. Injectionof the magnesium particles through a lance can be used, but this methodrequires large volumes of transport gas, otherwise the magnesiumparticles melt prior to being injected into the molten cast iron thusresulting in the plugging of the lance. The large volumes of transportgas can cause severe splashing, rendering the process impractical. Theaddition of magnesium particles on the surface of the molten cast ironis generally not used since much of the magnesium vaporizes before itcan modify the cast iron. Magnesium has a boiling point of about 2025°F. The cast iron in the ladle or melting pot is generally maintained atabout 2300-2850° F. As a result, the magnesium rapidly vaporizes oncontact with the molten cast iron and vaporizes into a gas withoutmodifying the cast iron. Several methods have been developed to increasethe recovery of the magnesium on the cast iron. For example, one methodinvolves magnesium deposited on the bottom of the melting pot or ladleand then being covered with reaction retarding steel plates, whereuponthe iron is poured over the magnesium. Other methods require similarcumbersome preparation.

The most common method for producing ductile and compacted graphite castiron alloys is to add ferrous metal alloys that include magnesium intothe molten cast iron. The ferrous metal alloys typically are made ofiron, silicon and magnesium so as to not introduce any undesiredsubstances into the cast iron. The ferrous metal alloy is introduced insolid form into the molten cast iron. The ferrous metal alloy slowlymelts in the molten cast iron and the magnesium in the ferrous metalalloy is recovered in much higher percentages than compared with addingpure magnesium to the cast iron.

The ferrous metal alloy is commonly made by smelting liquidferro-silicon alloys in dedicated furnaces and then tapping the liquidferro-silicon alloys in transport ladles and adding metallic magnesiumin the form of large ingots in the liquid bath in an amount sufficientto obtain the desired magnesium content in the ferro-silicon alloy.Another common method used to add magnesium to the ferro-silicon alloyis to add the metallic magnesium in the form of cored wire with themetallic magnesium contained in a rod formed by a steel sheath. In eachof these production methods, the liquid bath and the transport ladlemust be stirred, by mechanically stirring the bath with the addition,and/or by stirring with inert gas injected through a porous plug withinthe ladle and/or through a lance submerged into liquid bath. After thedesired amount of magnesium is obtained in the ferro-silicon alloy, theliquid ferro-silicon is poured out of the ladle for solidification forfurther use by the gray iron foundries. Another method used to addmagnesium to molten ferro-silicon alloy is the injection of magnesiumgranules through a refractory lance. Besides delivering the magnesiumdirectly to the bottom of the bath, at the end of the injection lance,the injection method enables the user to add other alloy fines as ablend with the magnesium granules. However, experience with injection ofmagnesium into molten pig iron in the steel industry has shown thatunless large quantities of transport gas are used, magnesium particlesinjected alone, without any carrier material, will tend to melt insidethe lance, thus plugging the transport pipe, resulting in much lost timeand expense in the unplugging of the lance. Unfortunately, the carriermaterials used for the injection of magnesium into molten pig iron, forexample lime and/or calcium carbide, can also introduce unwantedcontaminants into certain grades of ferro-silicon alloys.

In view of the present methods for the formation ofmagnesium-ferro-silicon alloys for the subsequent use in the alloying ofcast iron, there is a need for an improved method and additive for theformation of magnesium-ferro-silicon alloys which results in increasedamounts of magnesium alloying and which simplifies the alloying processand reduces the costs and wastes associated with the formation of themagnesium-ferro-silicon alloys. Moreover, these treatment agents andmethods used for introducing magnesium into the molten ferrous metal,ferro-silicon, can also be applied for the treatment with magnesium ofthe molten ferrous metal, cast iron, for the production of ductile castiron.

SUMMARY OF THE PRESENT INVENTION

The present invention overcomes the problem with adding magnesiumparticles by the injection of magnesium particles alone into theferro-silicon alloys by using an improved mixture of treatmentparticles. The present invention also simplifies the alloying process,eliminates the need for adding possible contaminates to themagnesium-ferro-silicon alloy, improves the amount of alloying of themagnesium in the ferro-silicon alloy, and/or reduces the amount of wasteassociated with the production of the magnesium-ferro-silicon alloy.However, the invention has broader applications in that the treatmentparticles can be directly added to molten iron to alloy and/ordesulfurize the molten iron without the use, or in combination with theuse, of a magnesium-ferro-silicon alloy.

In accordance with the principal aspect of the present invention,magnesium particles are injected into a ferro-silicon alloy by a lanceto alloy a desired amount of magnesium in the ferro-silicon alloy. Themelting of the metallic magnesium in the transport pipe of the lance isinhibited or overcome by mixing the magnesium particles with highmelting temperature particles. The high melting temperature particlesare designed to absorb heat as the high melting temperature particlesand the magnesium particles are transported through the lance and intothe ferro-silicon alloy. The absorption of heat by the high meltingtemperature particles inhibits or prevents the magnesium particles frommelting or completely melting prior to being injected into the moltenferro-silicon alloy. By inhibiting the melting of the magnesiumparticles in the lance, the problems associated with plugging of thelance during the magnesium alloying of the molten ferro-silicon alloy isovercome. In one embodiment, the magnesium particles are made of amajority of magnesium. In one aspect of this embodiment, the magnesiumparticles are made up of over 90% magnesium, preferably over 95%magnesium, and even more preferably over 98% magnesium. In anotherembodiment, the high melting temperature alloy particles are made up oftwo or more of the following metals, namely, aluminum, antimony,beryllium, boron, calcium, chromium, copper, iron, magnesium, manganese,nickel, rare earth metals, silicon, silver, sodium, strontium, tin,titanium, vanadium, zinc, zirconium, and mixtures thereof. In one aspectof this embodiment, the high melting temperature particles include ironand silicon. In another aspect of this embodiment, the high meltingtemperature particles include iron, magnesium and silicon. The specificcomposition of the high melting temperature particles is selected toobtain the desired heat absorbing characteristics of the particles whenused in combination with the magnesium particles. The specificcomposition of the high melting temperature particles is also preferablyselected to minimize contamination of the molten ferro-silicon alloy. Ascan be appreciated, if the final composition of the ferrous metal shouldnot include aluminum, the high melting temperature particle should notinclude aluminum so as not to introduce aluminum into the ferro-siliconalloy which in turn is later added to the molten ferrous metal. In stillanother embodiment, the high melting temperature particles include iron,silicon and magnesium or iron and silicon to avoid contamination of themolten ferrous material by unwanted elements. The use ofmagnesium-ferro-silicon alloy or ferro-silicon alloy as the high meltingtemperature particle simply adds more material of similar composition tothe molten ferro-silicon, thus not contaminating the ferro-silicon alloywith undesired elements. Materials commonly used as a carrier formetallic magnesium in other applications, such as hot metaldesulfurization, which include lime or calcium carbide, can introducecalcium to the magnesium-ferro-silicon alloy, which is unwanted forcertain grades of alloy. The present invention avoids the addition ofunwanted elements. However, certain grades of ferro-silicon require aminimum calcium content. For these grades, the use of lime or calciumcarbide as the material for the high melting temperature particles wouldbe very appropriate. In this embodiment, magnesium particles and limeand/or calcium carbide particles are injected into the moltenferro-silicon bath, with the aim of recovering both magnesium andcalcium from the injected particles.

In accordance with a further embodiment of the invention, the magnesiumparticles and high melting temperature particles are added to a ferrousalloy. In one aspect of this embodiment, the ferrous alloy issubstantially iron. In another aspect of this embodiment, the ferrousalloy is a ferro-silicon alloy. Preferably, the ferro-silicon alloyincludes 15-95% silicon and 5-85% iron. In accordance with still afurther embodiment of the invention, the magnesium particles are addedin a sufficient quantity to the ferrous alloy such that about 0.5-20%magnesium is alloyed in the ferrous alloy.

In accordance with another aspect of the present invention, the ratio ofhigh melting temperature particles to the magnesium particles isselected so as to ensure that the magnesium particles do notsufficiently melt in the lance to cause clogging of the lance during theinjection of the magnesium particles and high melting temperatureparticles into the ferro-silicon alloy. In one embodiment, the amount ofmagnesium particles in the particle mixture ranges from about 5% to 90%of the mixture, and preferably 60% to 90% of the mixture. The ratio ofthe metallic magnesium to the high melting temperature particles variesdepending on the type of molten alloy, e.g. ferro-silicon alloy, desiredand the composition of the high melting temperature particles.

In yet another aspect of the present invention, an injection lance isused to inject magnesium into the molten ferrous alloy (e.g.ferro-silicon alloy) and to improve the alloying of the magnesium in theferrous alloy. When the magnesium particles are stirred into a liquidbath of the molten ferrous alloy, significant amounts of magnesium arelost by vaporization as fumes and oxidation as white smoke when themagnesium melts in the molten ferrous alloy. The injection of magnesiumparticles through an injection lance immerses the magnesium particles inthe bath to minimize the oxidation of the magnesium and to reduce thevaporization of the magnesium prior to alloying with the ferrous alloy,thus allowing the magnesium to dissolve more completely in the moltenferrous alloy before it reaches the surface of the bath. Furthermore,the reduced loss of magnesium results in increasing economic benefitsfor the process. The conveying gases of the particles also assist instirring the particles in the molten ferrous alloy. As a result, theneed of a stirring device can be eliminated.

In still another aspect of the present invention, fines which aregenerated during the casting process of the ferro-silicon,magnesium-ferro-silicon alloy, or the like, can be recycled and used aspart of the high melting alloy particles in a subsequent magnesiumalloying process. By being able to recycle and remelt these metallicfines from past casting processes, increased recovery of the metalliccontent of the fines is obtained, resulting in increased economicbenefits of the alloying process and less waste. In accordance withstill another aspect of the present invention, the composition of thehigh melting temperature particles is selected to have a melting pointwhich is sufficiently high such that when such particles are combinedwith the magnesium particles and injected through the lance, the highmelting temperature particles absorb a sufficient amount of heat toprevent or inhibit the complete melting of the magnesium particles inthe lance. In one embodiment, the average melting temperature of thehigh melting temperature particles is about 2200° F.

In accordance with still yet another aspect of the present invention,the magnesium particles and the high melting temperature particles areinjected into the molten ferrous alloy (i.e. ferro-silicon alloy) as apre-blended mixture. In one embodiment, the magnesium particles and thehigh melting temperature particles are at least partially mixed prior toinjecting the particles into the lance. In one aspect of thisembodiment, the magnesium particles and the high melting temperatureparticles are substantially mixed prior to injection into the lance. Inanother embodiment, the magnesium particles and the high meltingtemperature particles are co-injected into a lance from separatedispensers and the particles are mixed in the lance prior to beingconveyed into the molten ferrous alloy. In this aspect of theembodiment, the magnesium particles are blended with at least 10% highmelting temperature alloy fines (e.g. ferro-silicon,magnesium-ferro-silicon, etc.) to reduce the chance of inadvertentcombustion of the magnesium particles during handling and transport. Inanother embodiment of the invention, the method of injection through alance consists of injecting through the single transport line, or from asecond set of injectors through a second transport line containing thesame lance, i.e. using a dual port lance. Preferably, the particles arefluidized as a suspension of particles in a carrier gas before beinginjected into the lance. The particle size of the magnesium particlesand the high-melting alloy particles is generally the same; however,they can be different. Preferably, the particles are coated with a flowtreatment agent such as glycol or a compound of silicon to enhance theirfluidization during transport to the lance. The fluidized particles canbe carried through the lance by a carrier gas. The carrier gas ispreferably inert. The carrier gases commonly used are argon, nitrogen,helium, natural gas, or various other non-oxidizing gases. Preferably,the carrier gas is nitrogen. Generally, the pressure of the carrier gasnecessary to inject the particles into the molten ferrous material isabout 20-90 psig; however, the pressure may be more or less depending onthe particle size of the particles and the depth in which the particlesare injected into the molten ferrous alloy. The injection of themagnesium particles into the molten ferrous material not only increasesthe alloying of the magnesium in the molten ferrous material, thetransport gases also increase the mixing of the particles in the moltenferrous alloy to facilitate in the even alloying and distribution of theparticles in the molten ferrous alloy.

In accordance with still a further aspect of the present invention, theparticles of magnesium and high melting temperature particles can beadapted for use in gray iron foundries. These foundries produce nodularcast iron in a process known as inoculation by introducing magnesiuminto the cast iron.

An object of the present invention is to provide a new alloy mixture andmethod of combining the alloying mixture with a molten ferrous materialto alloy magnesium with the molten ferrous material.

Another object of the present invention is to provide an alloyingmixture which includes a plurality of different particles.

Yet another object of the present invention is to provide an alloyingmaterial which includes high melting temperature particles to inhibit orprevent the melting of magnesium particles prior to particles beingcombined with the molten ferrous material.

In still yet another object of the present invention is to provide analloying mixture which can be inserted into a molten ferrous material byinjection.

A further object of the present invention is to mix magnesium particleswith high melting temperature particles prior to injecting the particlemixture into molten ferrous material.

Another object of the present invention is to use a lance orco-injection lance to inject metal alloying particles into moltenferrous material.

In still another object of the present invention is to improve thealloying of magnesium metal in molten ferrous material.

It is still yet another object of the present invention to reduce theloss of magnesium by vaporization or oxidation during the alloyingprocess.

A further object of the present invention is to provide an alloyingmixture which can include metal fines from a previous casting process soas to improve metal recovery and/or improve the economics of theprocess.

These and other objects of the present invention will become apparent toone skilled in the art upon reading the detailed description of theinvention in combination with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an injection process of injecting magnesium particlesand high melting temperature alloy particles into molten ferrousmaterial by an injection lance in accordance with the present invention;and

FIG. 2 illustrates a co-injection lance wherein magnesium particles andhigh-melting alloy particles are mixed in the injection lance prior tobeing injected into molten ferrous material.

PREFERRED EMBODIMENT OF THE INVENTION

Referring now to the drawings where the showing are for the purpose ofillustrating a preferred embodiment only and not for the purposes oflimiting the same, FIG. 1 illustrates one preferred arrangement forinjecting magnesium into a molten bath of ferro-silicon. As shown inFIG. 1 injection assembly 10 includes an injector 20 which is supportedby an injector frame 22 and includes an injector port 24 for dispensingparticles within injector 20 into an injection pipe 30. The particles ininjector 20 are a mixture of magnesium particles and particles of a highmelting temperature alloy such as ferro-silicon ormagnesium-ferro-silicon. The particle size of the magnesium particlesand the particles of high melting temperature alloy ar substantially thesame with an average particle size of less than about 1.5 mm, andpreferably between about 0.18 and 1.5 mm. The ratio of magnesiumparticles to the high melting temperature particles in injector 20ranges from about 5:95 to about 90:10. Preferably, the magnesiumparticles constitute a majority of the mixture, and preferably thecontent of high melting temperature particles is less than about 40% ofthe entire mixture. The particles in injector 20 are conveyed from theinjector by transport gas such as nitrogen through line 26 and intoinjector pipe 30. The particles may be fluidized in injector 20 prior toconveyance in injector pipe 30 to facilitate in the transport of theparticles in injector pipe 30. As shown in FIG. 1, the particles travelthrough injector pipe 30 through a flex section 32 and into lance pipe42 of lance 40. Lance 40 is positioned in ladle pit 90 by a lancehandler 120 which is mounted to ground surface G. Lance handler 120includes a lift pole 126, two lift arms 122 pivotally attached to liftpole 126, a lift cylinder 124 which elevates lift arm 122 and a liftadaptor mount 128 which secures lance pipe 42 to lift arms 122.

The particles traveling through lance pipe 42 exit the lance end 44 andinto molten ferro-silicon 80. The magnesium particles, upon contact withthe molten ferro-silicon 80, melt and vaporize in the ferro-silicon andeventually alloy with the ferro-silicon material in ladle 70. Thenitrogen carrier gas and some of the vaporized particles which do notalloy with the ferro-silicon alloy 80 bubble up through the surface offerro-silicon alloy 80 resulting in fumes 110 which are vented fromladle pit 90 through fume hood 100. The bubbling of these gases in theferro-silicon alloy 80 stirs the alloy to facilitate in magnesiumalloying and to make the composition of the ferro-silicon uniform.

Referring now to FIG. 2, an alternate embodiment of the invention isshown. In FIG. 2, two injectors 120, 130 are used to supply particles tolance 40. Injector 120 includes magnesium particles and high meltingtemperature particles. The ratio of magnesium particles to high meltingtemperature particles is about 1.1:1 to 10:1, and preferably 2:1 to10:1. Injector 130 contains high melting temperature material andlittle, if any, magnesium. The particles in injectors 120 and 130 can befluidized prior to conveyance through injector ports 122, 132 and intoinjector pipe 30. The particles in injector pipe 30 are conveyed tolance 40 by a transport gas which is fed through line 26 into injectorpipe 30. During transport in injector pipe 30, the particles frominjectors 120, 130 are mixed together. The particles in injector pipe 30travel through a flex section 32 and into lance pipe 42 of lance 40. Theratio of magnesium particles to the high melting temperature particlespassing through lance 40 is about 5:95 to about 90:10. The particlestravel through lance 40 and out lance end 44 into molten ferro-silicon80, which molten ferro-silicon is contained in ladle 70 in ladle pit 90.Preferably, at least 10% of the particles in injector 120 are highmelting temperature particles to reduce the chance of inadvertentcombustion of the magnesium particles during shipping and handling.Preferably, the conveying gas for each injector is the same.

The composition of the high melting temperature particles is selected sothat the melting point of such particles is substantially higher thanthe melting point of magnesium. In one preferred embodiment,ferro-silicon particles are used as the high melting temperatureparticles. In another embodiment, magnesium-ferro-silicon particles areused solely or in combination with ferro-silicon particles as the highmelting temperature particles. The use of one or both of these types ofparticles in the alloying process of molten ferro-silicon with magnesiumresults in not introducing contaminants into the ferro-silicon alloy. Inaddition, fines from the casting of the magnesium-ferro-silicon alloycan be recycled and later used as the high melting temperature particlesfor subsequent alloying of magnesium in another batch of ferro-siliconmetal. When ferro-silicon particles are used, the composition of suchparticles is generally about 15 to 95 percent silicon and 5 to 85percent iron. When magnesium-ferro-silicon particles are used, generallythe composition is 0.05 to 20% magnesium, 15 to 95% silicon, and 5 to85% iron. When additional metal alloys are to be included in theferro-silicon alloy composition, these alloys can be included with thehigh melting temperature particles and/or alloyed with such high meltingtemperature particles.

The composition of the magnesium particles is selected so that themagnesium particles contain a very high percentage of magnesium. Themagnesium content of the magnesium particles is at least 90 percentmagnesium, preferably 95 percent magnesium, and more preferably 98percent magnesium.

The particle sizes of the magnesium particles and the high meltingtemperature particles are selected so that proper and easy conveyance ofthe particles to the molten ferro-silicon metal is achieved. Metallicparticle sizes that are too small can create material handling safetyhazards. Particle sizes that are too large are difficult to fluidizeand/or can cause problems during conveyance such as becoming pluggedwithin the injection pipe. Preferably, the average particle size of themagnesium particles and the high melting temperature ferro-silicon ormagnesium-ferro-silicon particles is less than about 1.5 mm, andpreferably between about 0.18 and 1.5 mm.

The melting temperature of the high melting temperature particles isselected so as to absorb a sufficient amount of heat as the particlesare traveling through lance 40 so as to inhibit or prevent the magnesiumparticles from melting while inside the lance. This heat absorptioneffect of the high melting alloy particles overcomes the problems withpast injection processes using magnesium particles in that theabsorption of the heat by the high melting alloy particles inhibits themagnesium particles from melting thus reducing and/or substantiallyeliminating the clogging of the lance caused by molten magnesiumparticles. The high melting temperature particles are formulated so thatthe melting temperature of these particles is substantially higher thanthe magnesium particles. Preferably, the high melting alloy particleshave an average melting temperature of at least about 2200° F. Inaddition to selecting high melting metal temperature particles toinhibit the melting of the magnesium particles, sufficient quantities ofhigh melting temperature particles are combined with the magnesiumparticles so that a sufficient amount of heat is absorbed by the highmelting temperature metal particles. At least ten weight percent of theparticle mixture that is added to the ferro-silicon alloy 70 is highmelting temperature particles.

A general formulation of the magnesium-ferro-silicon after ferro-siliconis injected with the particle mixture includes (weight percent):

Iron  5-85 Magnesium 0.05-20   Silicon 15-95

A composition of the cast iron after the magnesium-ferro-silicon alloyis added to molten iron includes (weight percent):

Iron 80-98 Aluminum   0-0.2 Carbon 1.8-4   Chromium 0-5 Copper 0-3Magnesium 0.02-0.1  Manganese 0.2-2   Molybdenum 0-1 Nickel  0-20Silicon 0.8-17 

As can be appreciated, the process of alloying molten ferro-silicon canbe used to also alloy and/or desulfurize cast iron or other ferrousmaterials.

A non-oxidizing shielding gas can be used to protect the top of theferro-silicon molten alloy during the alloying with the particles.Shielding gasses such as argon, nitrogen, helium, and/or natural gas canbe used. The shielded environment primarily prevents oxygen frominteracting with the molten ferro-silicon alloy to reduce the amount ofslag being formed and reduce or prevent combustion of fumes escaping thesurface of the ferro-silicon alloy.

The invention has been described with reference to a preferredembodiment and alternates thereof It is believed that many modificationsand alterations to the embodiments disclosed will readily suggestthemselves to those skilled in the art upon reading and understandingthe detailed description of the invention. It is intended to include allsuch modifications and alterations in so far as they come within thescope of the present invention.

We claim:
 1. A method of alloying a ferrous material comprising: a)melting a ferrous material; b) inserting a lance into the molten ferrousmaterial until the end of the lance is at least partially submergedbeneath the surface of the molten ferrous material; c) injecting atreatment agent though said lance and into said molten ferrous materialto alter the composition of the molten ferrous material, said treatmentagent having a composition which at least partially inhibits the meltingof said treatment agent prior to said treatment agent entering saidmolten ferrous material thereby reducing the occurrence of plugging theend of said lance by melted treatment agent, said treatment agentincluding high melting temperature particles and magnesium particles,said high melting temperature particles including metal particles thatinclude at least two metals selected from the group consisting ofaluminum, antimony, beryllium, boron, calcium, chromium, copper, iron,magnesium, manganese, nickel, rare earth metals, silicon, silver,sodium, strontium, tin, titanium, vanadium, zinc, zirconium, andmixtures thereof, the ratio of said high melting temperature particlesto said magnesium particles being about 10:90 to 95:5.
 2. The method asdefined in claim 1, wherein said high melting temperature particlesinclude iron alloy particles, said iron alloy particles include iron andan iron alloying agent including a metal selected from the groupconsisting of aluminum, antimony, beryllium, boron, calcium, chromium,copper, magnesium, manganese, nickel, rare earth metals, silicon,silver, sodium, strontium, tin, titanium, vanadium, zinc, zirconium, andmixtures thereof.
 3. The method as defined in claim 1, wherein said highmelting temperature particles substantially consist of an alloy ofMg-Fe-Si, Fe-Si, and mixtures thereof.
 4. The method as defined in claim2, wherein said high melting temperature particles substantially consistof an alloy of Mg-Fe-Si, Fe-Si, and mixtures thereof.
 5. The method asdefined in claim 1, wherein said treatment agent includes lime, calciumcarbide, or mixtures thereof.
 6. The method as defined in claim 2,wherein said treatment agent includes lime, calcium carbide, or mixturesthereof.
 7. The method as defined in claim 3, wherein said treatmentagent includes lime, calcium carbide, or mixtures thereof.
 8. The methodas defined in claim 4, wherein said treatment agent includes lime,calcium carbide, or mixtures thereof.
 9. The method as defined in claim1, wherein the ratio of said high melting temperature particles to saidmagnesium particles being about 10:90 to 40:60.
 10. The method asdefined in claim 8, wherein the ratio of said high melting temperatureparticles to said magnesium particles being about 10:90 to 40:60. 11.The method as defined in claim 1, wherein said magnesium particlesinclude substantially pure magnesium.
 12. The method as defined in claim10, wherein said magnesium particles include substantially puremagnesium.
 13. The method as defined in claim 1, wherein said magnesiumparticles have an average particle size of less than about 1.5 mm. 14.The method as defined in claim 12, wherein said magnesium particles havean average particle size of less than about 1.5 mm.
 15. The method asdefined in claim 13, wherein said magnesium particles have an averageparticle size between about 0.18 and 1.5 mm.
 16. The method as definedin claim 14, wherein said iron alloy particles have an average particlesize between about 0.18 and 1.5 mm.
 17. The method as defined in claim1, wherein said high melting temperature particles have an averagemelting point of greater than about 2200° F..
 18. The method as definedin claim 4, wherein said high melting temperature particles have anaverage melting point of greater than about 2200° F..
 19. The method asdefined in claim 16, wherein said high melting temperature particleshave an average melting point of greater than about 2200° F..
 20. Themethod as defined in claim 1, including the step of adding saidtreatment agent in a sufficient quantity to said melted ferrous materialto form a magnesium-ferro-silicon alloy having a composition including:Iron 5-85% Magnesium 0-20% Silicon 15-95% 


21. The method as defined in claim 4, including the step of adding saidtreatment agent in a sufficient quantity to said melted ferrous materialto form a magnesium-ferro-silicon alloy having a composition including:Iron 5-85% Magnesium 0-20% Silicon 15-95% 


22. The method as defined in claim 6, including the step of adding saidtreatment agent in a sufficient quantity to said melted ferrous materialto form a magnesium-ferro-silicon alloy having a composition including:Iron 5-85% Magnesium 0-20% Silicon 15-95% 


23. The method as defined in claim 18, including the step of adding saidtreatment agent in a sufficient quantity to said melted ferrous materialto form a magnesium-ferro-silicon alloy having a composition including:Iron 5-85% Magnesium 0-20% Silicon 15-95% 


24. The method as defined in claim 19, including the step of adding saidtreatment agent in a sufficient quantity to said melted ferrous materialto form a magnesium-ferro-silicon alloy having a composition including:Iron 5-85% Magnesium 0-20% Silicon 15-95% 


25. The method as defined in claim 20, wherein saidmagnesium-ferro-silicon alloy has a composition including: Iron  5-85%Magnesium 0.05-20%   Silicon 15-95%


26. The method as defined in claim 21, wherein saidmagnesium-ferro-silicon alloy has a composition including: Iron  5-85%Magnesium 0.05-20%   Silicon 15-95%


27. The method as defined in claim 22, wherein saidmagnesium-ferro-silicon alloy has a composition including: Iron  5-85%Magnesium 0.05-20%   Silicon 15-95%


28. The method as defined in claim 23, wherein saidmagnesium-ferro-silicon alloy has a composition including: Iron  5-85%Magnesium 0.05-20%   Silicon 15-95%


29. The method as defined in claim 24, wherein saidmagnesium-ferro-silicon alloy has a composition including: Iron  5-85%Magnesium 0.05-20%   Silicon 15-95%


30. The method as defined in claim 1, including the step of adding saidtreatment agent in a sufficient quantity to said melted ferrous materialto form a ferrous mixture having a composition including: Iron 80-98%Aluminum   0-0.2% Carbon 1.8-4%   Chromium 0-5% Copper 0-3% Magnesium0.02-0.1%  Manganese 0.2-2%   Molybdenum 0-1% Nickel  0-20% Silicon0.8-17% 


31. The method as defined in claim 4, including the step of adding saidtreatment agent in a sufficient quantity to said melted ferrous materialto form a ferrous mixture having a composition including: Iron 80-98%Aluminum   0- 0.2% Carbon 1.8-4%   Chromium 0-5% Copper 0-3% Magnesium0.02-0.1%  Manganese 0.2-2%   Molybdenum 0-1% Nickel  0-20% Silicon0.8-17% 


32. The method as defined in claim 6, including the step of adding saidtreatment agent in a sufficient quantity to said melted ferrous materialto form a ferrous mixture having a composition including: Iron 80-98%Aluminum   0-0.2% Carbon 1.8-4%   Chromium 0-5% Copper 0-3% Magnesium0.02-0.1%  Manganese 0.2-2%   Molybdenum 0-1% Nickel  0-20% Silicon0.8-17% 


33. The method as defined in claim 18, including the step of adding saidtreatment agent in a sufficient quantity to said melted ferrous materialto form a ferrous mixture having a composition including: Iron 80-98%Aluminum   0-0.2% Carbon 1.8-4%   Chromium 0-5% Copper 0-3% Magnesium0.02-0.1%  Manganese 0.2-2%   Molybdenum 0-1% Nickel  0-20% Silicon0.8-17% 


34. The method as defined in claim 19, including the step of adding saidtreatment agent in a sufficient quantity to said melted ferrous materialto form a ferrous mixture having a composition including: Iron 80-98%Aluminum   0-0.2% Carbon 1.8-4%   Chromium 0-5% Copper 0-3% Magnesium0.02-0.1%  Manganese 0.2-2%   Molybdenum 0-1% Nickel  0-20% Silicon0.8-17% 


35. The method as defined in claim 1, wherein said high meltingtemperature particles are a ferro-silicon alloy.
 36. The method asdefined in claim 29, wherein said high melting temperature particles area ferro-silicon alloy.
 37. The method as defined in claim 34, whereinsaid high melting temperature particles are a ferro-silicon alloy. 38.The method as defined in claim 1, including the step of at leastpartially mixing together said high melting temperature particles andsaid magnesium particles prior to injecting said particles into saidmelted ferrous material.
 39. The method as defined in claim 29,including the step of at least partially mixing together said highmelting temperature particles and said magnesium particles prior toinjecting said particles into said melted ferrous material.
 40. Themethod as defined in claim 34, including the step of at least partiallymixing together said high melting temperature particles and saidmagnesium particles prior to injecting said particles into said meltedferrous material.
 41. The method as defined in claim 39, including thestep of at least partially mixing together said magnesium particles andsaid lime and/or calcium carbide particles prior to injecting saidparticles into said ferrous material.
 42. The method as defined in claim40, including the step of at least partially mixing together saidmagnesium particles and said lime and/or calcium carbide particles priorto injecting said particles into said ferrous material.